Devices and methods for vertebrostenting

ABSTRACT

The invention relates to a method of creating a curvilinear cavity within a vertebral body or other body structure. The invention also relates to devices that may be used to perform the steps to create the curvilinear cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 12/688,418 filed on Jan. 15, 2010, which is adivisional application of U.S. patent application Ser. No. 11/957,022,filed on Dec. 14, 2007 (now issued as U.S. Pat. No. 9,237,916), whichclaims priority to and the benefit of U.S. Provisional PatentApplication No. 60/875,114 filed Dec. 15, 2006, and U.S. ProvisionalPatent Application No. 60/875,173 filed Dec. 15, 2006. This applicationand U.S. patent application Ser. No. 11/957,022 are related to U.S.patent application Ser. No. 11/957,039 (now issued as U.S. Pat. No.7,909,873). The disclosures of U.S. patent application Ser. No.12/688,418, U.S. patent application Ser. No. 11/957,022, U.S. patentapplication Ser. No. 11/957,039, U.S. Provisional Patent Application No.60/875,114, and U.S. Provisional Patent Application No. 60/875,173 areall being incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to the field of orthopedicdevices to treat fractured bone in the spine, and more particularly toan orthopedic instrument and implant system that can be used tofacilitate bone cement treatment of a vertebral compression fracture.

BACKGROUND OF THE INVENTION

There are many disease states that cause bone defects in the spinalcolumn. For instance, osteoporosis and other metabolic bone conditionsweaken the bone structure and predispose the bone to fracture. If nottreated, certain fractures and bone defects of the vertebral body mayproduce intolerable pain, and may lead to the development of deformityand severe medical complications.

Bone weakening may also result from benign or malignant lesions of thespinal column. Tumors often compromise the structural integrity of thebone and thus require surgical stabilization and repair of defects withbiocompatible materials such as bone grafts or cements. Bone tumors ofthe spine are relatively common, and many cause vertebral compressionfracture.

More than 700,000 osteoporotic compression fractures of the vertebraeoccur each year in the United States—primarily in the elderly femalepopulation. Until recently, treatment of such fractures was limited toconservative, non-operative therapies such as bed rest, bracing, andmedications.

One surgical technique for treating vertebral compression fracture caninclude injecting or filling the fracture bone or bone defect withbiocompatible bone cement. A relatively new procedure known as“vertebroplasty” was developed in the mid 1980's to address theinadequacy of conservative treatment for vertebral body fracture. Thisprocedure involves injecting radio-opaque bone cement directly into afracture void, through a minimally invasive cannula or needle, underfluoroscopic control. The cement is pressurized by a syringe or similarplunger mechanism, thus causing the cement to fill the void andpenetrate the interstices of a broken trabecular bone. Once cured, thecement stabilizes the fracture and eliminates or reduces pain. Bonecements are generally formulations of non-resorbable biocompatiblepolymers such as PMMA (polymethylmethacrylate), or resorbable calciumphosphate cements which allow for the gradual replacement of the cementwith living bone. Both types of bone cements have been used successfullyin the treatment of bone defects secondary to compression fractures ofthe vertebral body.

One clinical issue associated with vertebroplasty is containment of thecement within the margins of the defect. For instance, an osteoporoticcompression fracture usually compromises portions of the cortical bonecreating pathways to cement leakage. Thus, there is a risk of cementflowing beyond the confines of the bone into the body cavity. Cementleakage into the spinal canal, for instance, can have grave consequencesto the patient.

Yet another significant risk associated with vertebroplasty is theinjection of cement directly into the venous system, since the veinswithin the vertebral body are larger than the tip of the needle used toinject the cement. A combination of injection pressure and inherentvascular pressure may cause unintended uptake of cement into thepulmonary vessel system, with potentially disastrous consequencesincluding embolism to the lungs.

One technique which has gained popularity in recent years is a modifiedvertebroplasty technique in which a “balloon tamp” is inserted into thevertebral body via a cannula approach to expand or distract thefractured bone and create a void within the cancellous structure.Balloon tamps are inflated using pressurized fluid such as salinesolution. The inflation of a balloon membrane produces radial forces onthe surface of the membrane and forms a cavity in the bone. Whendeflated and removed, the membrane leaves a cavity that is subsequentlyfilled with bone cement. The formation of a cavity within the boneallows for the injection of more viscous cement material, which may berelatively less prone to leakage.

In certain instances, such as the treatment of acute or mobilefractures, the balloon is also effective at “reducing” the fracture andrestoring anatomic shape to a fractured body. In particular, balloondilatation in bone is maximally effective if the balloon device istargeted inferior to, or below, the fracture plane. In this instance,the balloon dilatation may distract, or lift, a fracture bone fragment,such as the vertebral body endplate.

In other instances, such as chronic or partially healed fractures,balloons are less effective at “reducing” the fracture because radialforces are insufficient. Often the bone in an incompletely healingfracture is too dense and strong, and requires more aggressive cuttingtreatment, such as a drill or reamer tool to create a sufficient cavity.In these more challenging cases, the ability to inject bone cement intoa cavity created by a balloon or a reamer in the vicinity of thefracture is typically sufficient to stabilize the bone and relieve pain,even in the absence of fracture reduction.

One limitation to the use of such methods has been the difficulty intargeting the location at which the cavity should be created. Knowntechniques require access to the vertebral body using straight cuttingand reaming tools which are only able to access a limited region of thevertebral body being treated, generally only within one side of thevertebral body. A cavity created using these techniques can only treatone side of a vertebral body being targeted, resulting in an unevendistribution of bone cement that cannot completely stabilize thevertebral body. As a result, multiple entry points on different sides ofthe vertebral body are generally required in order to provide asymmetrical distribution of bone cement around a central axis of thevertebral body. These multiple entry points significantly increase thetime necessary for the procedure, the portion of the body being treated,and the amount of bone cement being injected, and, as such, cansignificantly increase the risks associated with treatment of a patient,as well as costs.

SUMMARY OF THE INVENTION

The present invention is directed towards novel methods and devices forpreparing a cavity in bone. The methods and devices disclosed herein canallow a cavity to be created in a vertebral body along a curvilinearpathway, allowing for a substantially symmetrical distribution of bonecement over a central vertical axis of a vertebral body. This can allowa vertebral body to be successfully and completely stabilized from asingle surgical access point and using a single stent device.

In one embodiment of the invention, a stent can include a multifilamentco-braided shaped structure which is collapsible to an elongated tubularshape suitable to fit within a tubular sheath assembled to a noveldelivery catheter. The outer wall of the stent is impregnated inpreferred regions with a polymer to form a thicker, relatively lesspermeable wall. The polymer impregnated co-braided wall is furtherperforated with holes or slots in preferred locations. An example cementdirecting stent for use with this invention is disclosed in U.S. PatentPublication No. 2005/0261781 A1 to Sennett et al., the disclosure ofwhich is incorporated by reference herein in its entirety. The stentgeometry is optimized to fit within a reamed or balloon-expanded cavitylocated approximately within the anterior ⅔ of a vertebral body. Thecavity is formed by a sequential method using a number of specificallydesigned instruments.

One aspect of the invention includes a method of forming a curvilinearvoid in bony structure. The method can include the steps of, accessing abony structure with a cannula, inserting a distal end of a drill devicethrough the cannula and into the bony structure, manipulating the distalend of the drill device to create a curvilinear void in the bonystructure, and removing the distal end of the drill device from the bonystructure and the cannula.

In one embodiment of the invention, the step of manipulating of thedistal end of the drill device can include a simultaneous rotation andcurvilinear translation of the distal end of the drill device. Thecannula can be substantially straight or include a curvature. Thedrilling device can include a flexible drill shaft assembly. Theflexible drill shaft assembly can include a sharp cutting tip, aflexible rotatable drive shaft coupled to the tip, and a flexible,moveable and non-rotatable housing.

In one embodiment, the step of manipulating the distal end of the drilldevice can include inducing a curvature in the distal end of theflexible drill shaft assembly. In one embodiment, the flexible drillshaft assembly can include a lever and cam sub assembly for varying aforce used to apply the curvature to the distal end of the flexibledrill shaft assembly.

One embodiment of the invention can also include the steps of moving thelever to a first position to reduce the force on the distal end of theflexible drill shaft assembly prior to inserting the distal end of thedrill device through the cannula, and moving the lever to a secondposition to increase the force on the distal end of the flexible drillshaft assembly after inserting the distal end of the drill devicethrough the cannula.

One embodiment of the invention can also include the step of moving thelever to the first position to reduce the force on the distal end of theflexible drill shaft assembly prior to removing the distal end of thedrill device from the cannula.

In one embodiment, the drilling device can include a locking feature.The method can further include locking the drill device into the cannulausing the locking feature prior to forming the void, and unlocking thedrill device from the cannula after forming the void and prior toremoving the distal end of the drill device. In one embodiment, thedrill device can be manipulated in response to a rotation of an elementat a proximal end of the drill device.

One aspect of the invention can include a method of enlarging acurvilinear void created in a bony structure. The method can include thesteps of inserting a distal end of a reamer device through a cannula andinto a curvilinear void created in a bony structure, for example by thedrill device, deploying a reaming element within the curvilinear void,wherein the reaming element is coupled to the distal end of a reamerdevice, manipulating the reaming element to enlarge the curvilinearvoid, returning the reaming element to an undeployed position, andremoving the distal end of the reamer device from the bony structure andthe cannula.

In one embodiment of the invention, the reamer device can include aflexible reamer shaft assembly coupled to the reaming element. Theflexible reamer shaft assembly can include a flexible rotatable driveshaft coupled to the reaming element, and a flexible, moveable andnon-rotatable housing. The reaming element may be deployed by a rotationof an element at a proximal end of the reamer device. The reamingelement may also be manipulated by a rotation of an element at aproximal end of the reamer device.

In one embodiment, the step of deploying a reaming element within thecurvilinear void can include inducing a curvature in a distal end of theflexible reamer shaft assembly. In one embodiment, the flexible reamershaft assembly can include a lever and cam sub assembly for varying aforce used to apply the curvature to the distal end of the flexiblereamer shaft assembly.

One embodiment of the invention can also include the steps of moving thelever to a first position to reduce the force on the distal end of theflexible reamer shaft assembly prior to inserting the distal end of thereamer device through the cannula, and moving the lever to a secondposition to increase the force on the distal end of the flexible reamershaft assembly after inserting the distal end of the drill devicethrough the cannula.

One embodiment of the invention can also include the step of moving thelever to the first position to reduce the force on the distal end of theflexible reamer shaft assembly prior to removing the distal end of thereamer device from the cannula.

In one embodiment, the step of manipulating the reaming element caninclude a simultaneous rotation and curvilinear translation of thereaming element, tracing a generally helical path. The distal end of thereamer device can initially be inserted to a distal end of thecurvilinear void. The curvilinear translation of the reaming element canbe in a retrograde direction, or in an anterior direction. The reamingelement can include a blade.

One aspect of the invention can include a method of deploying a stentwithin an enlarged curvilinear void created in a bony structure. Themethod can include the step of inserting a stent catheter assemblythrough a cannula and into a curvilinear void created in a bonystructure, wherein the stent catheter assembly can include a proximaldeployment mechanism, an internal flexible guidewire, a multifilamentbraided, polymer impregnated, self-expanding, cement-directing stentcollapsed on the distal end of the guidewire and restrained in acollapsed condition by a tubular polymer sheath, and connectablyattached to the distal end of the deployment mechanism by a hollow tubeassembly.

The method can further include the steps of deploying the self-expandingcement directing stent by slideably uncovering the tubular sheath torelease the stent to expand within the enlarged void within the bonystructure, removing the internal flexible guidewire, attaching a cementfilled cement injecting syringe to the proximal deployment mechanism,injecting cement into the proximal deployment mechanism through thehollow tube assembly into the stent, compacting the cement to cause thecomplete filling of the stent interior, terminating the filling when thevolume of cement injected meets or exceeds the nominal interior volumeof the expanded stent, and releasing the stent from the hollow tubeassembly.

One aspect of the invention can include a method of forming a void inbone on a curvilinear axis. The method can include the steps ofaccessing a bony structure with a cannula and inserting a telescopingtamp device into the cannula. The telescoping tamp device can include aflexible shaft assembly, comprising internal elastic curved wire and anouter hollow slotted tube concentric to, and secured to, the internalelastic curved wire, and a telescoping tubular handle bonded internallyto the internal wire, and externally to the outer hollow flexibleslotted tube.

In one embodiment, the method can also include the steps of locking thetelescoping tamp device into the cannula by a locking feature, creatinga void in bone by advancing the internal elastic curved wire relative tothe cannula to a preferred depth, advancing the hollow slotted tube overthe internal elastic curved wire to a preferred depth to enlarge thevoid, and removing the telescoping device from the cannula.

In one embodiment, the method can further include the steps of insertinga reamer device into the cannula and extending the reamer device fullywithin the curvilinear void, deploying the retractable blade within thecurvilinear void to enlarge the void, elongating the void along acurvilinear axis in a retrograde fashion by rotating a reamer deviceknob to cause the simultaneous rotation and curvilinear translation ofthe flexible reamer shaft assembly relative to the cannula along agenerally helical path, retracting the retractable blade assembly to theundeployed position, and removing the reamer device from the enlargedvoid and the cannula. The reamer device can include a flexible reamershaft assembly comprising a retractable blade subassembly in anundeployed position, a flexible rotatable drive shaft bonded to thesubassembly, and a flexible, moveable and non-rotatable housing.

In one embodiment, the method can also include the steps of inserting astent catheter assembly into the enlarged curvilinear void through thecannula, deploying a self-expanding cement directing stent by slideablyuncovering the tubular sheath to expand the stent within the enlargedvoid within the bony structure, removing an internal flexible guidewire,attaching a cement filled cement injecting syringe to a proximaldeployment mechanism, injecting cement into the proximal deploymentmechanism through the hollow tube assembly into the stent, compactingthe cement to cause the complete filling of the stent interior,terminating the filling when the volume of cement injected meets orexceeds the nominal interior volume of the expanded stent, and releasingthe stent from the hollow tube assembly.

In one embodiment, the stent catheter assembly can include a proximaldeployment mechanism, an internal flexible guidewire, a multifilamentbraided, and a polymer impregnated, self-expanding, cement-directingstent collapsed on the distal end of the guidewire, and restrained in acollapsed condition by a tubular polymer sheath, and connectablyattached to the distal end of the deployment mechanism by a hollow tubeassembly.

One aspect of the invention can include a method of forming a void inbone on a curvilinear axis. The method can include the steps ofaccessing a bony structure with a straight cannula, inserting a drilldevice comprising a flexible drill shaft assembly comprising a sharpcutting tip, a flexible rotatable drive shaft bonded to the tip, and aflexible, moveable and non-rotatable housing into the cannula, lockingthe drill device into the cannula by a locking feature, rotating a drilldevice knob to cause the simultaneous rotation and curvilineartranslation of the flexible drill shaft assembly relative to the cannulato generally trace a helical path, and unlocking the drill device fromthe cannula, and removing the drill device from the bony structure andcannula.

In one embodiment, the method can also include the steps of inserting aballoon catheter device comprising a flexible catheter shaft assembly, acompliant balloon structure located on the distal end of the catheterassembly, and a filling valve connected at the proximal end of thecatheter assembly, into the cannula and extending fully within thecurvilinear void, inflating the balloon structure, deflating the balloonstructure, and removing the balloon catheter device from the enlargedvoid and the cannula.

In one embodiment, the method can also include the step of inserting astent catheter assembly into the enlarged curvilinear void through thecannula, the stent catheter assembly comprising a proximal deploymentmechanism, an internal flexible guidewire, a multifilament braided,polymer impregnated, self-expanding, cement-directing stent collapsed onthe distal end of the guidewire, restrained in a collapsed condition bya tubular polymer sheath, and connectably attached to the distal end ofthe deployment mechanism by a hollow tube assembly.

One embodiment can also include deploying the self-expanding cementdirecting stent by slideably uncovering the tubular sheath to expand thestent within the enlarged void within the bony structure, removing theinternal flexible guidewire, attaching a cement filled cement injectingsyringe to the proximal deployment mechanism, injecting cement into theproximal deployment mechanism through the hollow tube assembly into thestent, compacting the cement to cause the complete filling of the stentinterior, terminating the filling when the volume of cement injectedmeets or exceeds the nominal volume of the expanded stent interior, andreleasing the stent from the hollow tube assembly.

In one embodiment, the method can also include the steps of inserting aballoon catheter device comprising a flexible catheter shaft assembly, acompliant balloon structure formed on the distal end of the catheterassembly, and a filling valve connected at the proximal end of thecatheter assembly, into the cannula and extending fully within thecurvilinear void, inflating the balloon structure, deflating the balloonstructure, removing the balloon catheter device from the enlarged voidand the cannula, and filling the void with bone cement.

One aspect of the invention can include a method of forming a void inbone on a curvilinear axis. The method can include the steps ofaccessing a bony structure with a straight cannula, inserting a drilldevice comprising a flexible drill shaft assembly comprising a sharpcutting tip, a flexible rotatable drive shaft bonded to the tip, and aflexible, moveable and non-rotatable housing into the cannula, lockingthe drill device into the cannula by a locking feature, rotating a drilldevice knob to cause the simultaneous rotation and curvilineartranslation of the flexible drill shaft assembly relative to the cannulato generally trace a helical path, unlocking the drill device from thecannula, and removing the drill device from the bony structure and thecannula.

In one embodiment, the method can also include the step of inserting astent catheter assembly into the enlarged curvilinear void through thecannula. The stent catheter assembly can include a proximal deploymentmechanism, an internal flexible guidewire, and a multifilament braided,polymer impregnated, self-expanding, cement-directing stent collapsed onthe distal end of the guidewire, and restrained in a collapsed conditionby a multi-lumen tubular polymer sheath, and connectably attached to thedistal end of the deployment mechanism by a hollow tube assembly.

One embodiment can also include injecting saline under pressure into theouter lumen of the multi-lumen tubular polymer sheath causing the distalend of the outer wall of the sheath to expand radially, withdrawingsaline from the outer lumen to cause the outer lumen to retract,deploying the self-expanding cement directing stent by slideablyuncovering the retracted tubular sheath to expand the stent within theenlarged void within the bony structure, removing the internal flexibleguidewire, attaching a cement filled cement injecting syringe to theproximal deployment mechanism, injecting cement into the proximaldeployment mechanism through the hollow tube assembly into the stent,compacting the cement to cause the complete filling of the stentinterior, terminating the filling when the volume of cement injectedmeets or exceeds the nominal volume of the expanded stent interior, andreleasing the stent from the hollow tube assembly.

Another aspect of the invention can include an apparatus for forming acurvilinear void in bony structure. The apparatus can include a handleand a flexible drill shaft assembly extending from a distal end of thehandle. The flexible drill shaft assembly can include a cutting tiplocated at a distal end of the flexible drill shaft assembly, a flexiblerotatable drive shaft coupled to the tip, and a flexible, moveable andnon-rotatable housing.

In one embodiment, the cutting tip is adapted to form the curvilinearvoid by simultaneous rotation and curvilinear translation of the cuttingtip. In one embodiment, the flexible drill shaft assembly is adapted toform a curvature at a distal end thereof. One embodiment furtherincludes a lever and cam sub assembly for varying a force used to applythe curvature. The lever can have a first position at which the force isless than at a second position of the lever.

Another aspect of the invention can include an apparatus for enlarging acurvilinear void created in a bony structure. The apparatus can includea handle and a flexible drill shaft assembly extending from a distal endof the handle. The flexible drill shaft assembly can include a pivotablereaming blade located at a distal end of the flexible drill shaftassembly, a flexible rotatable drive shaft coupled to the tip, and aflexible, moveable and non-rotatable housing.

In one embodiment, the reaming blade is adapted to pivot from a firstposition to a second position. In one embodiment, the reaming blade isadapted to form the curvilinear void by simultaneous rotation andcurvilinear translation of the reaming blade. In one embodiment, theflexible drill shaft assembly is adapted to form a curvature at a distalend thereof. One embodiment further includes a lever and cam subassembly for varying a force used to apply the curvature. The lever hasa first position at which the force is less than at a second position ofthe lever.

Another aspect of the invention can include an apparatus for treating avertebral body. The apparatus can include a handle, a flexible shaftassembly extending from a distal end of the handle, and a lever and camsub assembly for varying a force used to apply a curvature to a distalend of the flexible shaft assembly. In one embodiment, the lever has afirst position at which the force is less than at a second position ofthe lever.

The invention is also drawn to cannulas, drills, and reamers andcomponents thereof adapted for use with any of the methods describedabove.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention. In the followingdescription, various embodiments of the present invention are describedwith reference to the following drawings, in which:

FIG. 1A is a schematic plan view of a Jamshidi needle and K-wire, usedin accordance with one embodiment of the invention;

FIG. 1B is a picture of a Jamshidi needle being inserted into a patient,in accordance with one embodiment of the invention;

FIG. 2A is schematic perspective view of a trocar, used in accordancewith one embodiment of the invention;

FIG. 2B is schematic perspective view of a cannula, in accordance withone embodiment of the invention;

FIG. 2C is another schematic perspective view of the cannula of FIG. 2B;

FIG. 2D is a schematic perspective view of a trocar inserted with thecannula of FIG. 2B, in accordance with one embodiment of the invention;

FIG. 2E is a schematic plan view of a cannula, in accordance with oneembodiment of the invention;

FIG. 2F is a picture of a trocar and cannula being inserted into apatient, in accordance with one embodiment of the invention;

FIG. 3A is an exploded schematic perspective view of a drill assembly,in accordance with one embodiment of the invention;

FIG. 3B is a schematic perspective view of the drill assembly of FIG.3A;

FIG. 3C is a schematic side view of the drill assembly of FIG. 3A;

FIG. 3D is a schematic end view of the drill assembly of FIG. 3A;

FIG. 3E is a schematic perspective view of another drill assembly, inaccordance with one embodiment of the invention;

FIG. 3F is a schematic perspective view of the drill assembly of FIG. 3Einserted within a cannula, in accordance with one embodiment of theinvention;

FIG. 3G is a sectional side view of the drill assembly of FIG. 3Einserted within a cannula;

FIG. 3H is an enlarged sectional side view of the distal end of thedrill assembly of FIG. 3E;

FIG. 31 is an enlarged sectional side view of the proximal end of thedrill assembly of FIG. 3E inserted within a cannula;

FIG. 3J is a schematic plan view of a drill assembly, in accordance withone embodiment of the invention;

FIG. 3K is a picture of a drill assembly being inserted into a patient,in accordance with one embodiment of the invention;

FIG. 4A is a schematic perspective view of a reamer assembly, inaccordance with one embodiment of the invention;

FIG. 4B is a schematic perspective view of the reamer assembly of FIG.4A inserted within a cannula, in accordance with one embodiment of theinvention;

FIG. 4C is a sectional side view of the reamer assembly of FIG. 4Ainserted within a cannula;

FIG. 4D is an enlarged sectional side view of the distal end of thereamer assembly of FIG. 4A;

FIG. 4E is an enlarged sectional side view of the proximal end of thereamer assembly of FIG. 4A inserted within a cannula;

FIG. 4F is a schematic plan view of a reamer assembly, in accordancewith one embodiment of the invention;

FIG. 4G is a picture of a reamer assembly being inserted into a patient,in accordance with one embodiment of the invention;

FIG. 5A is a schematic perspective view of a needle being inserted intoa vertebral body, in accordance with one embodiment of the invention;

FIG. 5B is a schematic perspective view of a drill assembly beinginserted through a cannula into a vertebral body, in accordance with oneembodiment of the invention;

FIG. 5C is a schematic perspective view of a reamer assembly beinginserted through a cannula into a vertebral body, in accordance with oneembodiment of the invention;

FIG. 6A is a schematic side view of a drill assembly with a lever anddrill cam, in accordance with one embodiment of the invention;

FIG. 6B is a schematic perspective view of the drill assembly of FIG.6A;

FIG. 6C is a schematic end view of the drill assembly of FIG. 6A;

FIG. 6D is a schematic side view of the handle of the drill assembly ofFIG. 6A;

FIG. 6E is a schematic cross-sectional side view of the handle of thedrill assembly of FIG. 6A through a central elongate axis of the drillassembly;

FIG. 7A is a schematic side view of a lever and cam sub assembly in aclosed position, in accordance with one embodiment of the invention; and

FIG. 7B is a schematic side view of the lever and cam sub assembly ofFIG. 7A in an open position.

DETAILED DESCRIPTION OF THE INVENTION

To maximize the effectiveness of balloon dilatation or bone cutting witha reamer, it would be beneficial to more effectively target the locationwithin the bone prior to dilatation of the balloon. In the specific caseof vertebral body fracture, there are anatomical challenges to targetingwith minimally invasive instrumentation. Safe passage of instruments andballoon catheters from the posterior surgical approach is generallyachieved through a straight cannula positioned within the pedicle of thevertebral body, or just lateral to the pedicle to avoid potentiallydangerous penetration of the cannula in the spinal canal. Thisanatomically defined trajectory often does not align with, or target,the fracture within the vertebral body. Therefore, there are limitationsin current techniques to effectively target the fracture.

There are numerous devices disclosed in the art to make the injection ofcement into the vertebral body a safer procedure. One novel device, animplantable cement-directing stent device, is disclosed in U.S. PatentPublication No. 2005/0261781 A1 to Sennett et al., the disclosure ofwhich is incorporated herein by reference in its entirety. Theimplantable cement-directing stent device provides a means totemporarily stabilize a fractured vertebral body after cavity creationduring cement injection, while also directing the flow of cementanteriorly within the vertebral body to prevent unwanted cement flownear the spinal canal. This disclosure presents additional novel devicesand methods of use to fully describe the technique of “vertebrostenting”to treat vertebral compression fracture using conventional stent devicesor the improved stent device of Sennett et al.

Needle

In one embodiment of the invention, access to the vertebral body can beachieved using a pointed needle or wire to pierce the skin andunderlying tissue and entering into the pedicle, a depression of thevertebral body, until the needle is held fast. The needle can then bepressed into the vertebral body until it is held firmly in place by thewall of the vertebral body. The needle can then become a guide for theplacement of subsequent devices.

In an example embodiment of the invention, a Jamshidi needle and K-wirearrangement can be used to provide a guide for placement of subsequentdevices into the vertebral body. A Jamshidi Needle is a long, taperedcombination needle and drill that can be used for insertion into bone.An example Jamshidi needle and K-wire can be seen in FIG. 1A. Here, theJamshidi needle 110 can include a tapered distal end 120 and a handle130 at its proximal end. The elongate Jamshidi needle 110 can be hollow,to allow insertion of the K-wire 140 through the needle 140.

In operation, the tapered distal end 120 is inserted through the skinand underlying tissue and pressed against the outer wall of thevertebral body. The K-wire 140 can then be inserted through the hollowelongate needle 110 such that the distal end of the K-wire is forcedagainst the wall of the vertebral body. The Jamshidi needle 110 andK-wire 140 can be forced into the wall of the vertebral body to anydepth appropriate for the procedure. The Jamshidi needle 110 can then beremoved, leaving the K-wire 140 in place to act as a guide needle forthe placement of subsequent devices. An example of a Jamshidi needle 110and K-wire 140 inserted through the skin and underlying tissue of apatient can be seen in FIG. 1B. In alternative embodiments, anyappropriate needle type or other device may be used to provide initialaccess to the vertebral body.

Cannula & Trocar

In one embodiment of the invention, access to the vertebral body can beachieved through the use of a trocar and cannula assembly. This trocarand cannula assembly can be inserted over an already inserted guide wireor needle, such as the K-wire described above, or be inserted directlywithout the need for a guide wire.

One embodiment of a trocar and cannula assembly is shown in FIGS. 2A-2F.In this embodiment, the trocar and cannula assembly 200 can include atrocar 210 and a cannula 220. An example trocar 210 is shown in FIG. 2A.In this embodiment, the trocar 210 includes a hollow shaft 230 with asharpened tip 240, and an impact handle 250 or knob coupled to thehollow shaft 230. The impact handle 250 also has a cylindrical lockingflange 260, for releasable interlocking with the cannula 220. The trocar210 can be configured to fit over a guide wire or needle.

An example cannula 220 is shown in FIGS. 2B and 2C. The hollow cannula220 can include a thin walled straight tube 270 and a handle 275 with alocking feature 280 attached to the hollow tube 270. The locking featurecan include a button, slide, latch, or other appropriate mechanism forreleasable engagement with a flange. In the embodiment of FIGS. 2B and2C, the locking feature 280 includes a locking slide 280 and a lockingslide latch 295, wherein the locking slide latch 295 is configured toengage with the locking slide 280 and releasably hold the locking slide280 in either a closed or open position. The thin walled tube 270 canalso have a slot 285 along its axis on the proximal side that iscontinuous with a slot 290 in the handle 275. The tube slot 285 and thehandle slot 290 can be used for instrument orientation or drills,reamers, etc. disposed in the cannula 220.

The handle 275 may be coupled to the thin walled straight tube 270 ofthe cannula 220 by any appropriate means, including, but not limited to,bonding, pressure fitting, threading, or any combination thereof. Thehandle 275 may be a plastic, metal, or any other suitable material. Thehandle 275 can include a locking feature for releasable retention of aninstrument placed within the cannula 220. In one embodiment, the handle275 can include a number of holes through its length, fitted withstainless steel rods, that may be used by the surgeon, underfluoroscopy, for circumferential orientation of the handle 275 and thecannula 220 to ensure the desired relationship between the cannula 220and the vertebral body.

In one embodiment, the trocar 210 fits within the thin walled straighttube 270 of the cannula 220, and releasably locks to the locking feature280 of the cannula 220 via the locking flange 260. When locked together,the sharp tip 240 of the trocar 210 can protrude beyond the end of thethin walled straight tube 270 of the cannula 220. In an alternativeembodiment, the cannula may include a flexible hollow tube, or a curvedhollow tube, allowing the cannula to be placed over a curved guide wireor other curved object.

In use, the trocar 210 and the cannula 220 may be deployed over a guideneedle or wire and pressed into the vertebral body, with the trocar 210providing the displacement and/or cutting means needed to force thecannula through the skin and underlying tissue of a patient and upagainst, and possibly through, the wall of a vertebral body. The guidewire may be a K-wire 140 as described above, or be any other appropriateneedle, piercer, or guiding wire element. Once the cannula 220 isinserted through the outer wall of the vertebral body, the trocar 210and guide needle can be removed, leaving the hollow cannula 220 in placeas an access passageway for subsequent instruments and tools.

An example of a trocar 210 and guide wire 140 inserted through a cannula220 can be seen in FIG. 2D. In FIG. 2D, the impact handle 250 of thetrocar 210 is releasably coupled to the handle 275 of the cannula 220 bythe locking feature 280. In one embodiment, the trocar tip 240 canprotrude beyond the end of the thin walled straight tube 270 of thecannula 220 and can be rotated relative to the cannula tube 270, ifdesired. The entire trocar 210 and cannula 220 assembly is placed overthe guidewire 140, that was previously inserted into the vertebral body.In one embodiment, a small mallet can be used to tap the trocar 210 toenlarge the hole until the cannula 220 is pressed into the vertebralbody to a desired depth. The trocar 210 can then be unlatched from thehandle 275 and withdrawn. At this point, the needle or guidewire 295 canalso be removed, leaving the cannula 220 in place and held immovably bythe wall of the vertebral body.

An example embodiment of a cannula 220 and handle 275 can be seen inFIG. 2E. An example of this cannula 220 inserted into a patient can beseen in FIG. 2F.

Drill

In one embodiment of the invention, once the cannula is in place, thenext step is to drill a curved hole in the vertebral body. The curvedhole may be needed to make a cavity in the vertebral body that will goacross the interior of the vertebral body so that medical cement willfill and support the entire vertebral body without the need to drillfrom both sides. One embodiment of the invention can include a means ofproviding a drilled curved path in the vertebral body through the use ofa curved drilling device. Example curved drilling devices are shown inFIGS. 3A-3I.

In one embodiment of the invention, as shown in FIGS. 3A and 3B, thecurved drill device 300 can include a drive handle 305, a sharp tip 310attached to a flexible torque transmitting drive shaft 315, and a handledrive assembly 320. The flexible drive shaft 315 can be secured andcontained by a spring loaded, flexible, slotted metal tube 322 having afeedscrew assembly 324 attached therewith. The proximal end of the driveshaft 315 can include a solid tube 326 bonded, or otherwise coupled, tothe flexible shaft 315 component and having sufficient torquetransmission capability to drive the shaft assembly. The rotatingshaft/sharp tip 310 assembly can further be coupled to the handleassembly 320 by a cross pin 328, or other appropriate device, which canengage with a nut 344 located within the handle 305 and threaded ontothe feedscrew assembly 324.

The handle drive assembly can include a number of components, including,but not limited to, a cap 330 for the handle, a clamp 332 for the torquetube, a locking element 334 for the torque tube, and a retainer element336 for the torque tube. The retainer element 338 can be coupled to aspring element 340 to provide a spring force to a band or other elementconfigured to provide a force to the distal portion of the flexibledrive shaft 315 and slotted metal tube 322 to produce the correctcurvature at the distal end of the drill 300.

One embodiment of the invention can include an inner tube sized to slidewithin the outer slotted tube. This inner tube can have an extensivelaser cut opening along its distal portion. When assembled, the reducedcross section of this section of the inner tube lies adjacent to theslotted portion of the outer tube along the inside or concave side ofthe slotted tube. A compression spring of optimized stiffness can becoupled to the inner tube and the outer slotted tube at the proximal endby a lock washer, or other appropriate mechanism, that can be secured toa slot in the proximal end of the inner tube. When the washer isengaged, a tensile force is induced on the inner tube which causes theouter tube assembly to bend at the distal end. Upon bending, the slotson the medial side, which have been designed with gradually decreasingdepth to encourage sequential distal to proximal deflection, can close.Therefore, when fully assembled under load of the spring, the outerslotted metal tube can assume a curved orientation with a desired radiusof curvature. Since the slotted metal tube is itself flexible being madefrom hard temper stainless steel, or other appropriate material, it canbe straightened against the force of the spring to pass through astraight cannula.

In one embodiment, the drive handle of the drill 300 can be a two partassembly featuring a grip feature suitable to allow manual rotation,coupled to a rotator component having locking flange. The locking flangecan be designed to mate with the locking feature of a cannula handle toprevent axial movement but allow rotation. The rotator component canhave a female thread throughout its length which can mate with afeedscrew slotted tube assembly. The feedscrew and a key are welded, orotherwise coupled, to the proximal end of the slotted tube.

When assembled to the hollow cannula, the key component 342 canslideably mate with the hollow cannula axial slot, which canrotationally lock the drill's curved slotted tube 322 in a preferredcircumferential orientation. Therefore, when the handle assembly isrotated, the slotted tube advances in a fixed rotational orientationrelative to the handle assembly at a pace equal to the thread pitch ofthe feedscrew. The rotating flexible drive shaft assembly, which isaxially constrained within the slotted metal tube 322, also advanceswith the pitch of the feedscrew. The sharp rotating tip 310, by thecombined forces of the feedscrew advance and internal spring forcecurving the shaft, cuts and advances on a curved helical path when thehandle is rotated. Conversely, when the handle is counter rotated, thesharp tip retracts along the same curved helical path. If the lockengaging the curved drill is disassembled from the cannula, the devicemay be slideably removed from the cannula.

In operation, the distal end of the curved tube 322 of the drill can beslotted, perforated, composed of a different and or thinner material, orotherwise adapted to promote bending of the distal end. Any appropriatematerial, such as stainless steel, aluminum, or other metal, or aplastic or composite material may be used for the drilling device, aslong as the material can provide sufficient strength, flexibility,resiliency, and resistance to fatigue. In one embodiment, differentcomponents of the drilling device can be constructed from differentmaterials, including any of the materials described herein.

Another example of a curved drilling device is shown in FIGS. 3E-3I. Asshown in FIG. 3E, the curved drilling device 360 can include a drill tip362, a drill shaft 364 with a slotted portion 366 at the distal end forbending, an orientation key 368, a drill feed unit 370 complete with alocking flange 372 and a handle 374 for rotation.

The curved drilling device 360 releasably attached to a cannula andhandle assembly 220 is shown in FIG. 3F. In one embodiment of theinvention, when the curved drilling device 360 is initially installedinto the cannula 376, the protrusion is only that of the drill tipbeyond the cannula and as such, the slotted portion of the drill shaftis contained in the cannula and is therefore straight and not curved.The distal end of the drilling device 360 is free to curve once it hasbeen deployed beyond the distal end of the cannula.

A cross-section of the curved drilling device 360, depicting theinternal mechanisms of the system, is shown in FIG. 3G. More detailedenlarged cross-sectional diagrams are provided in FIGS. 3H and 3I. InFIG. 3H the distal end of the drill unit is illustrated. In thisembodiment, the drill tip 362 can be welded, bonded, threaded, orotherwise coupled, to a cabled torque tube 378 that provides rotation ofthe tip 362. The torque tube 378 may be an array of wires wound in ahelical, circular manner that provides torque strength with theflexibility to “go around the corner” to deliver the necessary power tothe drill tip 362 to cut bone. A drill safety cable 380 can be coupledto the drill tip 362 to promote drill tip retrieval in the unlikelyevent that it becomes detached from the cabled torque tube 378.

The slotted portion of the drill tube 366 is bent into a desired arc asit exits the cannula. This is achieved by means of the band 382, locatedon the inside of the bend and firmly attached to the drill shaft 364 atits distal end and attached to a compression spring assembly 384 at itsproximal end. As a result, the band 382 can be held under springtension, thus pulling on the inside of the drill shaft 364 to produce anarc, as desired.

FIG. 31 is a detailed cross section of the drill unit and handle, inaccordance with one embodiment of the invention. In one embodiment, thelocking flange on the drill unit can be retained by the locking flangeof the handle. That, in turn, can be held in place by the locking slide280 on the handle. The locking flange component can also have aninternal thread or drill feed nut.

In one embodiment of the invention, a feed screw 386 includes a matchingmale thread. The proximal end of the drill shaft can be affixed to thefeed screw 386 by welding, bonding, threading, or other means, and thefeed screw 386 and drill shaft can have a key, also attached by weldingor other means, to ensure the desired circumferential orientation of thedrill shaft within the cannula 220. The key interface can align thehandle plane to the plane of the curved drill shaft. One embodiment canalso include a compression spring 388 for providing a pulling force onthe band in order to bend the distal end of the drill shaft to thedesired arc. A band retention device 390 can contain the compressionspring 388. The compression can be preloaded to a desired force and theband retained to ensure that there is always tension on the band. In oneembodiment of the invention, the spring 388 may be compressed as theband is pulled distally to allow for straightening of the drill shaftwhen passing through the cannula.

In one embodiment, the torque tube 392 can go through the drill shaftand feed screw, as well as through the band retention device, and befastened to the handle 374 by the torque retention device 394 that iskeyed to the rotation handle 374. The drill safety cable can go throughthe entire length of the torque tube and the excess can be tied into aknot. Alternatively, a ferrule can be staked to the drill safety cableso that it does not slide out of the torque tube inadvertently.

In operation, according to one embodiment of the invention, as thehandle 374 is rotated the pins in the handle interact with the slots inthe drill feed unit and cause it to rotate. This action causes the feedscrew to move and advance the drill while rotating the drill tip 362 forcutting. This motion allows the drill tip 362 to cut a curvilinear paththrough the interior of the vertebral body. The progress of the pathwaycan be monitored by use of a medical imaging technique, or be measuredby means of a distance scale associated with the drill and indicatingthe extension of the drill tip beyond the end of the cannula.

An example embodiment of a drill assembly can be seen in FIG. 3H. Anexample of this drill assembly inserted into a patient can be seen inFIG. 3I.

Reamer

In one embodiment of the invention, the curved path created by the drilldevice can be enlarged by a reamer device. Enlarging the cavity canallow it to accommodate the stent and that medical cement that willultimately be injected into the cavity. An example of a reamer device isshown in FIGS. 4A-4G.

In one embodiment, the distal end of the reamer is configured forinsertion through a cannula into a vertebral body. The reamer caninclude an orientation key configured to mate with a corresponding slotin the cannula to ensure that the distal end of the reamer is deployedat the correct circumferential angular orientation. The reamer may bereleasably lockable in the cannula.

In one embodiment, the reamer can include a circumferentially partiallyslotted outer tube, wherein the slots enable the distal end of thereamer to bend in a predetermined direction. The reamer may include aband inserted within the outer slotted tube and coupled to the distaland the proximal ends of the reamer to bend the slotted outer tube in apredetermined direction and at a set angle. The proximal end of the bandmay be coupled to a compression spring to provide a predetermined amountof flex to the distal end of the reamer, thus allowing the distal end tobe straightened while being inserted through the cannula, and thenreturn to its predetermined bent configuration upon being extendedbeyond the end of the cannula.

The reamer may include a reamer blade yoke configured to extend from thedistal end of the outer slotted tube. A reamer blade may be pivotablycoupled to the reamer blade yoke by a pivot pin. The reamer may includea cabled torque tube coupled to the reamer blade yoke to rotate thereamer blade yoke and coupled reamer blade while the outer slotted tuberemains stationary. A cable may be extended through the cabled torquetube and coupled to the reamer blade to provide a force to pivot theblade about the pivot point from a neutral, centered configuration to atilted/opened configuration. The cable may be attached, at the proximalend of the reamer, to a compression spring. The compression springattached to the cable can eliminate slack in the cable and allow theangle of the reamer blade to elastically deflect from its set angle.

In one embodiment, the proximal end of the reamer may include a handle.The handle may include a blade opening sleeve. Rotation of the bladeopening sleeve can open or close the reamer blade with or withoutrotating the blade. The handle may also include a rotation handle.Rotation of the rotation handle can rotate the reamer blade about thereamer blade yoke. Rotation of the rotation handle can also provide aproximal movement of the distal end of the reamer back towards thedistal end of the cannula;

In operation, in one embodiment of the invention, rotation of the reamerblade, while opening the blade, results in a semi-spherical cavity beingcreated. Once the blade is fully opened, rotation of the rotation handleprovides a rotational movement and a proximal movement of the reamerblade, allowing the reamer blade to follow a generally helical path tocreate a curved, generally cylindrical cavity of a length determined bythe amount of rotation of the rotation handle. The proximal end of thereamer may include markings to indicate the amount of proximal movementof the distal end of the reamer from an original, fully extendedposition. Rotation of the blade opening sleeve in the opposite directioncan return the reamer blade to a neutral/centered orientation. Uponreturning the reamer blade to the neutral/centered orientation, thereamer may be unlocked and removed from the cannula.

In one embodiment, the reamer device may be similar in construction tothe drill devices described above. Both devices can have a slotted tubeassembly and a flexible torque transmitting drive shaft containedtherein. Both devices can have an internal tube welded, bonded, orotherwise coupled at the distal end, and joined by a washer andcompression spring at the proximal end. However, the reamer device canhave a moveable blade disposed at its tip. The moveable blade can beattached to a yoke by a pivot pin, and to a cable tether that iscrimped, bonded, welded, or otherwise attached to the moveable blade ata location distal to the pivot pin.

More specifically, a reamer device 400 for enlarging the drilled cavityto a desired diameter and curvilinear length is shown in FIG. 4A. Thereamer device 400 may have similarities to the drilling device describedabove in that it has a shaft 405 that is slotted at the distal end 410for curving, and the curving is produced by a band that is spring loadedby a compression spring situated between the feed screw and the bandretention device. In this embodiment, the reamer device 400 includes areamer blade 415 that is pivotably coupled to a yoke 420 that is mountedon the distal end of the shaft 405. An orientation key 425 may bemounted to the shaft 405 to engage with a slot in a cannula and ensurethe correct circumferential orientation of the reamer device uponinsertion. At its proximal end, the reamer device 400 can include a dualfunction handle 428 including rotation handle 430 for rotating the blade415, a blade opening sleeve 435 for deploying the blade, and a reamerfeed nut 440 for moving the blade back and forward along the axis of theshaft as the blade is rotated. The proximal end of the handle 430 may bea tubular molded component with gripping features on its externalsurface. In an alternative embodiment, the handle 430 may bemanufactured from any appropriate metal, plastic, ceramic, compositematerial, or combination thereof. Rubber or fabric elements may also beplaced on the outer surface of the handle 430 to promote grip.

The reamer device 400 releasably attached to a cannula and handleassembly 220 is shown in FIG. 4B. A cross section of the reamer device400, depicting the internal mechanisms of the system, is shown in FIG.4C. More detailed cross-sectional diagrams are provided in FIGS. 4D and4E.

In one embodiment, the reamer assembly may also be retained in thecannula and handle assembly 220 in the same manner as described abovefor the drilling device. The reamer feed nut 440 may work in the sameway as described above for the drilling device feed nut. In oneembodiment, a torque tube 445 can provide power for reaming (enlarging)the drilled hole, with the torque tube 445 driving the yoke 420 thathouses the pivoting reamer blade 415. An inner cable 450 that goesthrough the center of the torque tube 445 can be used to tilt or openthe blade 415 from the neutral position aligned with the axis of theshaft 405 to a deployed position at an angle to the axis of the shaft405. The blade 415 can tilt or pivot about a pivot pin 455 coupled tothe reamer blade yoke 420. As with the drilling device above, thecurvature of the distal end of the reamer device 400 can be set by aband 460 placed within the slotted tube 410 and held in tension by aspring element at the proximal end of the reamer device 400. The fullydeployed angle may be set at any appropriate angle. In one embodiment,the deployment angle may be set at any angle up to 90°. For example, thefully deployed angle may be in a range from 20° to 90°, or from 30° to70°, or from 45° to 60°.

The curvature of the distal end may be set to any appropriate angle bycorrect selection of the band length. A band retention device 462 canhold the band 460 at the proximal end of the reamer device 400, with acompression spring 464 coupled to the band retention device 462 to allowthe shaft 405 to flex from its preferred steady state curvature duringdeployment through the cannula 220 and upon contact with a “hard”element within the vertebral body.

The reamer device 400 can include a multi-component, dual functionhandle. A cross-section of an example handle is shown in FIG. 4E. In oneembodiment of the invention, a lost feed motion may be needed to openthe reamer blade, while rotating the reamer handle, with the feed systemremaining still. This feature is provided by means of a blade openingsleeve 435. In one embodiment, this may be achieved by a rotation of thehandle to initially “telescope” the handle from the blade opening sleeve435 to pull on the center cable 450 to open the reamer blade 415 allwhile no feeding motion occurs. A torque tube retention device 470travels in an elongated slot in the rotation handle 430 so no proximalmovement results. The blade opening sleeve 435 retains a “T” screw 475that provides the proximal movement of the handle for blade opening andwhen a blade opening nut 480 stops on the head of the T screw 475,rotation is now transferred to the reamer feed nut 440.

The reamer feed nut 440 rotation pulls the feed screw 484 proximally andat the distal end the reamer blade is rotating and feeding proximallyresulting in cutting bone and creating a curved cavity to desired lengthwith fluoroscopy, or other appropriate means, for visual reference.After the desired length of cavity has been achieved, the rotatinghandle 430 is rotated counter to the cutting direction and the reamerblade 415 will fold back inward to the center starting position. Thereamer assembly can be unlatched from the handle and removed. Thecannula and handle assembly 220 can remain in place, however, so thatfurther devices, such as devices that permit the insertion of the stentand the medical cement, can be inserted into the enlarged cavity.

The cable 450 originating from the moveable blade may be fed through theentire assembled device and terminated and crimped, or otherwisecoupled, to a cable retainer 490, such as a cross pin assembly, that iscoupled to the wall of the rotation handle 430. A spring 492 may belocated within the proximal inner border of the rotation handle 430adjacent to the cable retainer 490. A thread may be used to couple therotation handle 430 to the remainder of the reamer device 400.

In one embodiment, the dual function handle 428 may induce a tensileforce on the cable tether 450 by rotating the proximal molded componentrelative to the distal handle component to effectively lengthen thehandle. The cable tether thereby pulls the moveable blade 415 to cause apivoting of the blade from a closed to an open position. The handle 428can then cause the rotation of the flexible drive shaft assembly torotate the blade 415 within the cavity.

The handle assembly, including the distal and proximal components, maybe further secured to a rotator component having an internal threadmating the feedscrew component 484 of the slotted tube assembly. Thus,its function may be substantially identical to that of the drillingdevice described above. However, the feedscrew rotation may not beenabled until the reamer blade has been fully deployed via rotation ofthe proximal component of the handle 428. Therefore, in one embodiment,when the rotation handle 430 is rotated, the moveable blade assemblyfirst rotates and deploys, then translates due to the action of thefeedscrew mechanism 484. The deployed blade therefore enlarges the pathto a required diameter by simultaneously rotating and translating theblade 415. The direction of translation, in one embodiment, isretrograde, which is achieved by the use of a left hand thread in thefeedscrew 484.

In one embodiment, the blade deployment from a neutral to an openposition may only occur when the blade is rotating. In an alternativeembodiment, the blade deployment may be independent of the bladerotation. The rate of blade deployment from a closed to an open positionis dependent on the pitch of the thread which joins the proximal anddistal handle component.

In an alternative embodiment, the reamer device may be configured todrill into the vertebral body as it is advanced, before being deployedto extend the size of the cavity, as described above. In thisembodiment, the reamer device can function as both a reamer and a drill,thus eliminating the need for a separate drilling device.

An example embodiment of a reamer device can be seen in FIG. 4F. Anexample of this drill assembly inserted into a patient can be seen inFIG. 4G.

Method of Use

The devices discussed herein may be used in conjunction to provide amethod of creating a curvilinear cavity within a vertebral body, orother bony structure. As disclosed herein, the creation of a curvilinearpathway and cavity within a vertebral body allows the cavity to extendover a potentially larger region of the interior of a vertebral body,and bisect an axis of the vertebral body using only a single point ofaccess. After creation of a cavity in a damaged or diseased vertebralbody, the cavity can be filled with a medical cement or other treatmentelement to stabilize the vertebral body and alleviate pain. As a result,the creation of a curvilinear pathway and cavity using these devices canenable the complete stabilization of a vertebral body from a singleaccess incision, thus reducing the time needed for a surgical procedureand the damage caused to surrounding tissue and bone during a procedure.This can greatly improve the efficiency and safety of such a procedure.

In one embodiment of the invention, a procedure for using the devicesdisclosed herein can be used to produce a curvilinear cavity within avertebral body. One example embodiment of the invention further includesa method of placing a stent within a vertebral body. The stent can be aself-expanding, covered stent that allows interdigitation and preventsleakage of bone cement in undesired directions. In one embodiment, asingle stent can be placed at a mid-line location of a vertebral body,rather than placing multiple stents on either side of the mid-line, thusreducing the time and fluoroscopy exposure require during a surgicalimplantation procedure.

In one embodiment, the method of creating a cavity for within avertebral body, or other bony body, can include first creating aposterior pathway to the vertebral body, using a extrapedicular orintrapedicular approach, with a Jamshidi needle and/or K-wire. This maybe performed, for example, using a dual C-arm technique to place andmedialize the Jamshidi needle/K-wire to the fullest extent.

A working channel and trocar assembly can then be inserted along thepathway created by the Jamshidi needle/K-wire. This can be performed,for example, by locking the trocar into the working channel, insertingthe working channel into the pathway, and tapping the assembly intoplace until the distal tip of the trocar and working channel extends, inone embodiment, 1-3 mm beyond the posterior wall of the vertebral body.The trocar can then be removed, leaving the open working channel inplace.

A curved pathway through the vertebral body can then be created using acurved drill. This may be achieved using any of the drill arrangementsdescribed herein. In one embodiment, the drill depth markings at theuser interface are set to “0” mm prior to insertion into the workingchannel. The drill can then be locked into the working channel with thekey facing in the medial direction, thus ensuring the correct directionof curvature of the drill within the vertebral body. The handle of thedrill can then be rotated to advance the drill tip into the vertebralbody, with fluoroscopy, or some other appropriate technique, used todetermine when the desired depth of penetration is achieved. The drillcan then be removed and the depth markings on the user interfacerecorded. In one embodiment, the drill tip is oriented in thecontralateral anterior quadrant of the vertebral body, thus assuringproper cavity positioning and bilateral cement filling.

In one embodiment, a larger cavity can then be created within thevertebral body by reaming out the hole created by the curved drill witha curved reamer. This may be achieved, for example, by first setting thedepth markings on the user interface of the reamer to match thoserecorded for the drill depth, thus assuring that the reamer ispositioned correctly within the vertebral body. The reamer can then beadvanced fully into the pathway created by the drill and locked into theworking channel, with the position of the reamer confirmed usingfluoroscopy or some other appropriate technique. The blade of the reamercan then be opened, for example by rotating a portion of the handle ofthe reamer, and reaming can be carried out by rotating the handle. Inone embodiment, the reamer may be stopped approximately 1-3 mm beforeapproaching the distal tip of the working channel, with the positionconfirmed by fluoroscopy, or some other appropriate technique. The bladecan then be closed (for example by rotating a portion of the handle inthe opposite direction), and the reamer removed. In one embodiment, dueto blade deflection, the cavity created by the reamer can have a slighttaper from the distal end to the proximal end.

Once a cavity has been created, a stent delivery system can be lockedinto the working channel to correctly position a stent within thevertebral body. Once the stent has been positioned, a sheath coveringthe stent can be removed to deploy and expand the stent, and cement canbe injected into the stent by attaching a syringe to the proximal end ofthe delivery system. The desired amount of cement can be injected intothe stent with fluoroscopy, or some other appropriate technique, beingused to monitor the flow of cement into the stent. Once the requisiteamount of cement has been injected, the stent can be released from thedelivery system and the delivery system removed from the workingchannel, thus leaving the stent in place within the vertebral body. Theworking channel can then be removed and the access pathway sutured orotherwise closed.

In one example embodiment, the pedicle of the vertebral body is firstlocated. A needle assembly is then inserted percutaneously from theposterior approach through the outer tissue and anchored into the boneof the vertebral body to a suitable depth. This needle or wire willprovide a guide for subsequent instruments. In one embodiment, theneedle is a 1.5 mm diameter stainless steel pointed wire, although inother embodiments any appropriate diameter and material of needle may beused. The needle may be solid or hollow, depending upon the specificrequirements of the procedure. An example of a guide wire or piercer 510being inserted through the outer tissue 515 of a patient and into avertebral body 520 by a posterior approach can be seen in FIG. 5A.

Once the guide wire 510 is in place, a trocar can be inserted into, andreleasably coupled to a cannula, and the resulting trocar and cannulaassembly slid over the guide wire 510. The trocar impact knob can betapped with a hammer or other instrument to force the trocar forward toenlarge the hole in the vertebral body and thereby force the tip of thetrocar and cannula into the bone. Once the trocar and cannula assemblyhave been correctly positioned, the trocar and the guide wire can beremoved, thus leaving the cannula in place on its own. This cannula canthen serve as a delivery path into the vertebral body for subsequentinstruments.

A curved drilling device can then be inserted through the cannula tocreate a curvilinear pathway through the vertebral body. An example of adrilling device 525 being inserted through a cannula 530 and into avertebral body 520 can be seen in FIG. 5B.

The drilling device 525 can be slideably placed within the cannula byaligning the key on the drill 535 with the slot on the cannula. Thedrilling device 525 can then be fully inserted and releasably locked tothe cannula 530 by sliding a locking tab to the lock position, orotherwise securing the drilling device 525 to the cannula 530. In thisposition, the curved slotted tube of the drilling device 525 isconstrained in the straight tube of the cannula 530 and the sharp drilltip is positioned at the end of the cannula 530. After the drillingdevice 525 is secured to the cannula 530, for example by the locking theflange to the cannula handle, the drive handle of the curved drill canbe rotated to cause the rotation of the flexible drive shaft assemblyand sharp tip. Rotation of the flexible drive shaft assembly and sharptip can also cause the simultaneous translation of the slotted tube andfeedscrew assembly relative to the drive handle and cannula 530, thustranslating the tip of the drilling device 525 into the vertebral bodyalong a curvilinear path, provided the handle is locked to the cannula.For example, as it is being fed forward, the distal end of the drillshaft will begin to protrude from the cannula and starts to curve in thedesired direction as it is cutting. The farther the drill shaft exitsfrom the cannula, the greater the curved protrusion. As the drill tiprotates and travels in an arc, the resultant hole that it creates isalso in an arc until the desired depth is achieved.

The sharp tip advances within the bone according to the pitch of thefeedscrew. The advance of the tip of the drilling device 525 may bemonitored fluoroscopically by the user, and/or the depth of drilling maybe indicated by a scale printed or etched on the drilling device 525.When the path has been fully formed, the lock may be disengaged and thedrilling device 525 removed from the cannula 530. The drilling device525 can be removed by a counter rotation of the drill handle to withdrawthe drill back into the cannula 530 and straighten the drill shaft inthe process, after which the locking flange can be released and thedrill assembly removed from the cannula 530. In an alternate embodiment,the drilling device 525 can be removed by simply unlatching it from thecannula 530 and pulling it out. This will, in turn, leave a hollow,curvilinear path through the vertebral body extending from the end ofthe cannula.

A curved reamer device can then be inserted through the cannula toenlarge the curvilinear pathway through the vertebral body created bythe drilling device. An example of a reamer device 540 being insertedthrough a cannula 530 and into a vertebral body 520 can be seen in FIG.5C.

The reamer device 540 can be preset to provide a desired protrusion,based on the depth of the path created by the drilling device, withreamer device 540 set to a depth that matches the drilled depth. Thereamer device 540 can then be inserted through the cannula 530 to thefull extent of the previously drilled cavity along the same circularpath. The reamer device 540 can then be releasably locked or latched tothe cannula 530. During insertion of the reamer device 540, the moveableblade of the reamer is set in an undeployed position, locatedsubstantially along the axis of the shaft, so it may easily pass throughthe cannula 530. In one embodiment, the position of the reamer tip canbe fluoroscopically confirmed within the center of the vertebral body.

The handle of the reamer device 540 can then be rotated to deploy androtate the blade, with the reamer blade pivoting outward from the shaftand cutting a semi-sphere to a desired diameter at the distal end of thecavity, without backward movement. This therefore forms a substantiallysemi-spherical terminus of a cavity in the bone at the end of thecurvilinear path.

Once fully deployed, the blade can rotate and translate in retrogradefashion back toward the cannula 530 along a generally helical path inresponse to further rotation of the handle of the reamer device 540. Theblade rotating action forms a generally curvilinear elongated hole. Thespeed of translation and cutting is dependent on the pitch of thefeedscrew mechanism in the handle. The cavity created by the reamerdevice 540 may be monitored fluoroscopically to determine the length ofthe cavity, or the length may alternatively be monitored by a printedscale on the device.

When cavity cutting is complete, the proximal end of the handle may becounter rotated to relax tension on the tether cable and allow themovement of the blade back to the closed or undeployed position. Thereamer device can then be unlocked from the cannula 530 and removed. Theresulting curvilinear cavity 550 is then free to have a treatmentdevice, such as a stent and/or treatment material, such as bone cement,inserted into it.

The cannula 530 can then remain in place for insertion of other devicesthat will fill the cavity with medical cement. In one embodiment, thesedevices may include a stent and stent deployment apparatus, wherein thestent is filled with cement through the stent deployment apparatus tofill the curvilinear cavity and stabilize the vertebral body. After thecement injection procedure has been completed, the cannula 530 can beremoved and the surgical incision closed.

Another embodiment of the invention can include a drill and/or reamerdevice including a lever and cam sub assembly or other mechanism toallow tension to be reduced in the spring assembly. This can allow thespring force providing the curvature to the drill or reamer to bereduced during insertion and/or removal of the elongated tube assemblyand drill tip, thus easing the insertion and removal of the drill orreamer from the working channel during use. An example curved drilldevice 600 including a lever and cam sub assembly, with the distal endof the drill straightened, can be seen in FIGS. 6A through 6E.

In the embodiment shown in FIGS. 6A-6E, the curved drill device 600 caninclude a drive handle 605, a sharp drill tip 610 attached to a flexibletorque transmitting drive shaft 650 positioned within a slotted tubeassembly 615, and a handle drive assembly positioned within the handle605. The slotted tube assembly 615 can be a spring loaded, flexible,slotted metal tube. A key component 620 can be located on the slottedtube assembly 615 to ensure that, during operation, the drill 600 isinserted and locked into the working channel, such as a hollow cannula,in the desired circumferential orientation. A drill feed nut 625including a locking flange 630 can be threaded onto the handle driveassembly 680 located within the handle 605. with the locking flange 630providing a locking element for releasably locking the drill 600 to acannula. A cable retaining pin 635 can be inserted within, and keyed to,the handle 605 to provide a torque retention device to anchor theproximal end of the flexible torque transmitting drive shaft 650. Thecable retaining pin 635 can then drive the shaft 650 as the handle 605is rotated.

The handle drive assembly 680 within the handle 605 includes a feedscrew 655 onto which the feed nut 625 can be threaded. The cableretaining pin 635 is located within a cam pusher assembly 660 locatedwithin the central portion of the handle 605. A band retention element665 is used to anchor a band 670 located within the slotted tubeassembly 615, and anchored at its distal end to a distal portion of theslotted tube assembly 615, to provide the force necessary to produce acurvature at the distal end of the drill 600. A compression spring 675is positioned between the feed screw 655 and the band retention element665 to provide a spring force to the band retention element, therebyallowing the curvature of the distal end of the drill 600 to flex.

In addition, the curved drilling device 600 includes a lever 640attached to a drill cam 645 mounted on the proximal end of the handle605, wherein the lever 640 pivots the drill cam 645 about a central axisupon actuation by a user. The drill cam 645 includes an eccentric innerportion that abuts against a cam pusher assembly 660 located within thecentral portion of the handle 605. The cam pusher assembly 660 abutsagainst the band retention element 665, or other intermediate element.The band retention element 665 provides a stop for the compressionspring element 675 located within the central axis of the handle 605 andconfigured to provide a spring force to the band retention element 665,thus providing the required force to the band 650 in order to maintainthe distal end of the slotted tube assembly 615 in a curvedconfiguration.

In operation, when the lever 640 is closed against the handle 605 of thedrill 600, the compression spring 675 pushes the band retention element665 and cam pusher assembly 660 against the drill cam 645, and providesthe force necessary to produce a curvature at the distal end of thedrill 600. However, when the lever is pulled away from the handle 605,it pivots the drill cam 645 about its axis and, due to the eccentricconfiguration of the drill cam 645, forces the cam pusher assembly 660and band retention element 665 against the spring element 675. This hasthe effect of compressing and foreshortening the spring element 675,thus reducing the force provided to the distal end of the slotted tubeassembly 615 and therefore allowing the distal end of the slotted tubeassembly 615 to be straightened with less or minimal effort.

In another embodiment of the invention, a reamer, such as any of thereaming devices described herein, could include a lever and cam subassembly or other mechanism to compress and foreshorten a compressionspring within the handle of the reamer, thus allowing the distal end ofthe slotted tube assembly of the reamer to be straightened with less orminimal effort.

A simplified example lever and cam sub assembly 700 is shown in FIGS. 7Aand 7B. In this embodiment, the lever 705 and cam 710 pivot about anaxis 715. An anchoring element 720 is forced against the side of the cam710 by a compression spring 725. A mounting element 730 holds the distalend of the compression spring 725 at a fixed position with respect tothe cam axis 715. An elongate element 735 is anchored to the anchoringelement 720 and extends through the center of the compression spring 725and mounting element 730. In an alternative embodiment, the mountingelement 730 may be moveable with respect to the cam axis 715, forexample through a threaded screw arrangement.

In operation, when the lever 705 is in a closed position 750, as shownin FIG. 7A, the spring pushes the anchoring element 720 against thesmall radius side 740 of the cam 710, resulting in the anchoring element720 providing a force holding the elongate element 735 in a firstposition close to the axis 715. When the lever 705 is moved to an openposition 760, as shown in FIG. 7B, the large radius side 745 of the cam710 pushes the anchoring element 720 away from the axis 715, resultingin the spring element 725 being compressed and foreshortened. As aresult, the anchoring element 720 and elongate element 735 are held in asecond position extending further away from the axis 715. It should benoted that the position of the lever is infinitely variable within itsrange of motion and can, in one embodiment, be held at any location byfriction between the closed position and the open position, thusproviding any intermediate position for the anchoring element 720 andthe elongate element 735 and resultant intermediate force.

In one embodiment, the elongate element 735 is a band anchored at itsdistal end to a distal end of a slotted tube assembly for a curved drilland/or reamer device. In this embodiment, turning the lever 705 from aclosed position 750 to an open position 760 will reduce the tension onthe band and allow the distal end of the slotted tube assembly to bestraightened more easily (i.e. without the need for a force sufficientto overcome the spring force provided by the compression spring 725).However, even when the lever 705 is in the closed position 750, byincluding the spring element 725, the distal end of the drill or reamercan still be straightened if it is subject to a force sufficient toovercome the spring force. As a result, the distal end of the drill orreamer is free to increase or decrease its curvature as required, if itabuts against a more solid object capable of overcoming the spring forceon the distal end of the slotted tube assembly and deflecting the tip ofthe drill. In an alternative embodiment, the spring element 725 can beremoved and the anchoring element 720 can be rotatably coupled directlyto the cam 710.

In one embodiment, the anchoring element 720 can include, but is notlimited to, at least one of a cam pusher assembly, a band retentionelement, a bushing, a flange, a handle portion, and/or any otherappropriate anchoring element for a portion of a curved drilling and/orreaming device. In one embodiment, the mounting element 730 can include,but is not limited to, a feed screw, a bushing, a feed nut, a flange, ahandle portion, or any other appropriate mounting element for a portionof a curved drilling and/or reaming device. The elongate element 735 caninclude a band, a wire, a shaft, a tube, a sheath, or any otherappropriate elongate member for use in a curved drilling and/or reamingdevice.

In an alternative embodiment, the anchoring element 720, mountingelement 730, and/or elongate element may be portions of a stent deliverydevice adapted to deploy a stent within a cavity created within avertebral body, or be portions of any other appropriate devices used forthe treatment of vertebral bodies or other bones.

In an alternative embodiment, the lever and cam sub assembly can bereplaced by a screw assembly, a slider assembly, a trigger assembly, arotating helix assembly, or any other appropriate assembly or mechanismfor moving the anchoring element 720 with respect to the mountingelement 730 to compress and foreshorten the spring element 725.

In one embodiment, the elongate element 735 can include an elementproviding a restoring force to straighten the distal end of a drill orreamer. This can allow the lever to provide a controllable curvature tothe distal end of the drill or reamer, with the increase in anglethrough which the lever is turned corresponding to a decrease in thecurvature of the distal end of the drill or reamer. Indicator markingson the handle of the drill can then be used to allow a user to set thedistal end of the drill or reamer to any desired curvature by turningthe lever to the desired location.

In alternative embodiments of the invention, any appropriate material,or combination of materials, may be used for the components describedherein. Appropriate materials include, but are not limited to, stainlesssteel, aluminum, plastics, textiles, composite materials, or anycombination thereof. The method of creating a cavity may include all, oronly some of, the components described herein, depending upon thespecific requirements of the system.

In further alternative embodiments of the invention, different drilland/or reamer devices can be used to create the cavity. These mayinclude one or more blades or drill bits, looped or otherwise configuredwires, or other drilling, boring, or reaming devices. The blades may beof any appropriate shape and configuration.

In one embodiment of the invention, a fiber optic camera device may beinserted into the cannula to provide images of the curvilinear pathwayand cavity to a physician at any point during the procedure. The cameramay also provide diagnostic information that may be used whendetermining the required size and shape of the cavity being created.

In alternative embodiments of the invention, the arc of the drillingdevice and/or reamer device may be selected to provide any shape ofcurvilinear cavity. Different arcs may be provided by selection ofdifferent tools, with each tool being set to provide one specific arc.Alternatively, an individual device may be adaptably configured toprovide an arc of any required curvature. In further alternativeembodiments, drill and/or reamer devices can be used to create cavitieswithin other bones of a body or within any other structural element,such as, but not limited to, spinal disc tissue. As a result, themethods and apparatus described herein can be used in the treatment ofother bones within a body, such as, but not limited to, broken orotherwise damaged limb bones, or for disc fusion techniques.

It should be understood that alternative embodiments, and/or materialsused in the construction of embodiments, or alternative embodiments, areapplicable to all other embodiments described herein.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The foregoingembodiments, therefore, are to be considered in all respectsillustrative rather than limiting the invention described herein. Scopeof the invention is thus indicated by the appended claims, rather thanby the foregoing description, and all changes that come within themeaning and range of equivalency of the claims are intended to beembraced therein.

What is claimed is:
 1. A method of enlarging a curvilinear void createdin a bony structure, the method comprising the steps of: inserting adistal end of a reamer device through a cannula and into a curvilinearvoid created in a bony structure, the reamer device comprising aflexible reamer shaft assembly comprising (i) a pivotable reamingelement at a distal end thereof, and (ii) means for pivoting adjustablythe reaming element; deploying the reaming element within thecurvilinear void; manipulating the reaming element to enlarge thecurvilinear void; returning the reaming element to an undeployedposition; and removing the distal end of the reamer device from thecannula.
 2. The method of claim 1, wherein the flexible reamer shaftassembly is coupled to the reaming element.
 3. The method of claim 2,wherein the step of deploying a reaming element within the curvilinearvoid comprises inducing a curvature in a distal end of the flexiblereamer shaft assembly.
 4. The method of claim 3, wherein the flexiblereamer shaft assembly comprises a lever and cam sub assembly for varyinga force used to apply the curvature to the distal end of the flexiblereamer shaft assembly.
 5. The method of claim 4, further comprising thesteps of: moving the lever to a first position to reduce the force onthe distal end of the flexible reamer shaft assembly prior to insertingthe distal end of the reamer device through the cannula; and moving thelever to a second position to increase the force on the distal end ofthe flexible reamer shaft assembly after inserting the distal end of thedrill device through the cannula.
 6. The method of claim 4, furthercomprising the step of: moving the lever to the first position to reducethe force on the distal end of the flexible reamer shaft assembly priorto removing the distal end of the reamer device from the cannula.
 7. Themethod of claim 2, wherein the flexible reamer shaft assembly comprisesa flexible rotatable drive shaft coupled to the reaming element and aflexible, moveable and non-rotatable housing.
 8. The method of claim 1,wherein the reaming element is at least one of deployed and manipulatedin response to a rotation of an element at a proximal end of the reamerdevice.
 9. The method of claim 1, wherein the step of manipulating thereaming element comprises a simultaneous rotation and curvilineartranslation of the reaming element.
 10. The method of claim 9, whereinthe distal end of the reamer device is initially inserted to a distalend of the curvilinear void.
 11. The method of claim 10, wherein thecurvilinear translation of the reaming element is in a retrogradedirection.
 12. The method of claim 1, wherein the reaming elementcomprises a blade.
 13. An apparatus for forming a curvilinear void inbony structure comprising: a handle; and a flexible drill shaft assemblyextending from a distal end of the handle, comprising: a cutting tiplocated at a distal end of the flexible drill shaft assembly; a flexiblerotatable drive shaft coupled to the tip; and a flexible, moveable andnon-rotatable housing.
 14. The apparatus of claim 13, wherein thecutting tip is adapted to form the curvilinear void by simultaneousrotation and curvilinear translation of the cutting tip.
 15. Theapparatus of claim 13, wherein the flexible drill shaft assembly isadapted to form a curvature at a distal end thereof.
 16. The apparatusof claim 15 further comprising a lever and cam sub assembly for varyinga force used to apply the curvature.
 17. The apparatus of claim 16,wherein the lever has a first position at which the force is less thanat a second position of the lever.
 18. An apparatus for enlarging acurvilinear void created in a bony structure comprising: a handle; and aflexible drill shaft assembly extending from a distal end of the handle,comprising: a pivotable reaming blade located at a distal end of theflexible drill shaft assembly; a flexible rotatable drive shaft coupledto the tip; and a flexible, moveable and non-rotatable housing.
 19. Theapparatus of claim 18, wherein the reaming blade is adapted to pivotfrom a first position to a second position.
 20. The apparatus of claim18, wherein the reaming blade is adapted to form the curvilinear void bysimultaneous rotation and curvilinear translation of the reaming blade.